ML19330A779
| ML19330A779 | |
| Person / Time | |
|---|---|
| Site: | Satsop |
| Issue date: | 04/15/1980 |
| From: | Renberger D WASHINGTON PUBLIC POWER SUPPLY SYSTEM |
| To: | Engelken R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V) |
| References | |
| ELE-FJ-80-021, GO3-80-795, IEB-79-03, IEB-79-3, NUDOCS 8007290405 | |
| Download: ML19330A779 (33) | |
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. , B P W shington Public Power Supply System A JOINT OPERATING AGENCY S
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Docket flos. 50-508 and 50-509 v z g ' s Mr. R. H. Engelken, Director
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Walnut Creek, CA 94596 ,
Subject:
IE BULLETIN 79-03, " LONGITUDINAL WELD DEFECTS IN STAINLESS STEEL PIPE SP0OLS"
Reference:
Letter, D. L. Renberger to R. H. Engelken, same subject, dated. July 10, 1979
Dear fir. Engelken:
In the reference letter, we committed to perform an inspec-tion program on Youngstown welded pipe as used on the WNP-3/5 gas stripper. The attached program, which was conducted to satisfy that committment, reports no evidence of the longi-tLdinal weld defects which were discussed in the subject IE Bulletin.
With this letter WPPSS considers this issue closed.
Very truly yours, Mby D'. L. RENBERGER ASSISTANT DIRECTOR TECHNOLOGY l
DLR:FJ:crw I Attachment 8007290405 e @ ~N
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, n WASHINGTON PUBLIC POWER SUPPLY SYSTEM Inspection Program For IE Bulletin 79-03 Detection of Longitudinal Weld Defects in Stainless Steel Pipe Manufactured by Youngstown Welding and Engineering Company
>0 t f e Introduction The inspection program described f, this report is submitted in accordance with a commitment made to the NRC, in letter G03-79-1283 dated July 10, 1979, in response to IE Bulletin 79-03 dated March 12, 1979. This bulletin expressed concerns over possible defects in the longitudinal welds of ASME SA-312 type 304, welded (without filler metal) pipe manufactured by Youngstown Welding and Engineering Company.
Program Applicability This program is applicable to Youngstown manufactured SA-312 type 304 welded (without filler metal) pipe as used for the WNP-3 gas stripper regenerative heat exchanger shell. This program is not applicable to the UNP-5 gas stripper heat exchanger shell because, although it uses the same material specification, it is from a different manufacturer, Trent Tube Division of Colt Industries.
Examination Program Scope The examinations performed under this program are intended to satisfy the requirements of NRC IE Bulletin 79-03. They are limited to the longitudinal weld seam of ASME SA-312 type 304 welded (without filler metal) pipe manufactured by Youngstown Welding and Engineering Company as used in the WNP-3 gas stripper regenerative heat exchanger shell.
Description The subject heat exchanger shell is fabricated from 12"
. schedule 40S SA-312 type 304 pipe about 12' long (Youngstown heat #24701). One end of the pipe is welded to a weld neck flange (tube sheet end) and the other end is closed with an inset flat plate (see Figure 1) cap. The suspected weld defect is an unfused area in the center of the material between the ID and OD of the longitudinal seam weld. This is described as Centerline Lack of Penetration (CLOP).
Examination l l
Because CLOP can be a difficult condition to detect, the examinations are performed in two parts. The first part is an l acid etch of the exposed (cap) end of the pipe. The second part, performed af ter the acid etch, is an ultrasonic examina-tion of _ the full length of the longitudinal seam weld, except for two 4. inch long places at the U clamp supports for the l
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The results of the acid etch phase of the examination program showed no evidance of CLOP and are documented in Attachment 1 of this program' .
The ultrasonic examination is performed in accordance with the requirements of ASME SA-655, Special Requirements for Pipe and Tubing for Nuclear and Other Special Applications as required by ASME Section III, paragraph NB-2550 and NB-2551, Examination and Repair of Seamless and Welded (Without Filler Metal) Tubular Products and Fittings.
NOTE: Calibration reflectors are five percent deep notches one-eighth inch wide rather than one-sixteenth inch wide and are defined on drawing UTCB-TP-3-1 Rev. 1.
lhe ultrasonic examination part of thir program is performed using WPPSS Procedure QCI 6-13, Ultrasonic Examination of Piping Systems. With the above noted differences with regard to the calibration standard, this procedure is included as Attachment II to this p,rogram.
For the purposes of this program, the ultrasonic examinations are conducted using shear wave angle beam ( in the range of 45 0 to 75U)circumferential scans only, with the sound beams directed normal (perpendicular) to the plane of the longitudinal seam weld from each side of the weld. The actual angle (s) used will be determined by the optimum signal response during the procedure qualification process.
Recording of Indications All indications which produce an ultrasonic signal amplitude response equal to or greater than fifty percent of the primary reference response at reference sensitivity shall be recorded.
Evaluation of Indications All indications which produce an ultrasonic signal am'plitude response equal to or greater than 100% of the primary reference response at reference sensitivity shall be evaluated.
Rejection Criteria Indications in excess of the reference standard (amplitude and length of the five percent notch) are unacceptable unless the defects are eliminated or repaired in accordance with the requirements of the program.
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. e Repair Program Repairs, when required, shall be made in accordance with the requirements of Article IWB-4000 of Section XI of the ASME Code.
Ultrasonic Examination Results The results of the ultrasonic examinations showed no indications and, therefore, no CLOP and are contained in Attachment III of this program, including personnel certifications and the examination data sheets.
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After grinding with a disc grinder the area was hand finished to a 240 grit. This was followed by electropolishing using the Struers.2 Movipol portable electropolishing unit and Struers A2 polishing reagent'. A sufficient area of the seam weld was i polished to enable the pro' file of the weld to be identified j and the area of potential centerline lack of penetration (CLOP) to be examined.
- The polished areas were electrolytically etched using ten percent oxalic acid and the Struers. apparatus.
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The etched zone was examined by eye and by portable microscope j at magnifications of X50 and X100.
No evidence of CLOP was observed,
- The seam welds were probably solution heat treated af ter welding l and it was very difficult to obtain much definition of the microstructure of the weld. Hence no photographs were obtained.
' The attached figure shows the profile of the fusion zone observed l visually. In both cases there was substantial overlap between the inner and outer weld beads. The depth of penetration of the i
=. j outer weld' bead was approximately 1/4 to 5/16" in a 3/8" wall ;
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ULTRAS 0ti!C EXAMitiAT10:1 0F P!P!f!G SYSTEMS 1.0 PURPOSE AfiD SCOPE This instruction defines the method for manual contact ultrasonic exami-nation of piping components and systems to meet ASME Section XI require-ments.
l 2.0 DEF ifil TI0 tis tione 3.0 PROCEDURE 3.1 E 3 uipment and Personnel - Equipment and Personnel shall conform to the requirements of Ref erence 4.1 3.2 Calibration Blocks - The calibration blocks used for this exami- t nation shall conf orm to the requirements of Figure 1.
3.3 Surface Preparation - Tfte contact surface shall be clean and free of dirt, dust, weld spatter, loose paint, or other material which would in+erfere with free movement of the transducer or impair transmission of ultrasonic energy into the material. The minimum surface finish is 250 RMS.
3.4 Scannino Rate and Sensitivity 3.4.1 The manual scanning rate shall not exceed 6 inches per second. Each pass of,the search unit shall overlap a mini-l mum of 10 percent of the transducer width.
3.'4.2 Scanning shall be performed at 2X above the primary gain i
level (1X). Measurement and recording of indications shall be done at the primary level, 1X.
3.5 Straight Beam Calibration for Welds '
3.5.1 Calibrate the instrument sweep to read distance from the
. scanning surface .in inches, using the signals from the side drilled hole and the back reflection (Figure 1).
3.5.2 The calibration standard contains one side drilled hole l (SDil) at 1/2 T from the examination surf ace (Figure 1). ,
Position the search unit to obtain a peak signal amplitude l' from the 1/2 T_ side drilled hole *. Adjust the signal _ampli-tude to 80?. of full screen height. On the disp, lay screen, mark the position and amplitude of the calibration signal.
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. A d v.. A Draw a horizontal line across the display screen at the 80%
level. This horizontal line represents the primary ref-crence icvel (lX).
- Note: When using a dual element transducer, align the split line parallel with the long axis of the side drilled hole.
3.5.3 Record and Plot all calibration data on the data sheet -
(Figure 2A & 23).
3.6 Straight Beam Examination of Welds 3.6.1 An examination shall be performed to detect reflectors in the weld using straight beam longitudinal wave techniques.
The search unit shall be contacted to the weld surf ace and moved prugressively along and across the weld and heat af- i f ec h"z one (HAZ ) . When practical, examine the base metal for a minimum distance of 1 T from the edge of the weld. L 3.6.2 Penetration shall be verified by obtaining a reflection from an opposite surface of the wela being examined.
3.6.3 When a dual element transducer is used, it shall-be scanned over the weld twice with the split line oriented, (1) parallel to the weld circumference, and (2) transverse to the weld circumf er ence.
3.6.4 Record all data in accordance with the requirements of Paragraph 3.9 3.7 Angle Beam Calibration For Welds
- 3. 7 ;l The angle beam sweep is calibrated by using the 2 inch and 4 inch radial reflecting surf aces on the end of the II W-2 block. Calibrate the instrument sweep range for the metal .
path to be used. .
3.7.2 Construct a DAC curve using the following method:
- 1) Obtain a signal from the notch. located cn the opposite side, using the 1/2 "V" path method (See Figure 1).
Use the d3 control to bring this signal to 80%. Mark the location on the screen.
- 2) Obtain a signal f rom the notch, located on the contact side, using the full "V" path method. Mark the location on the screen.
Page 2 of 16
QCl 6-13 Rev. A
. 3) Con.nect the two points with a straight line. This is the primary DAC level.
3.7.3 Without changing the gain level, obtain the peak signal amplitude from the side drilled hole at 1/2 T. Mark the position and amplitude on the display screen.
3.7.4 Record and Plot all calibration data on the data sheet (Figure 2A & 28). ,
3.8 Anal _e Beam Examination of Welds 3.8.1 Coverage shall conform nominally to Figures 5 through 8.
3.8.2 Scanning for reflectors parallel to the weld shall be perf ormed by a f ull "V" path f rom one side of the weld or a one half "V" path f rom two sides of the weld, where practical. Examine all the weld and 1/2 T on both sides where practical.
3.8.3 Scanning for reficctors tr ansverse to the weld shall be perf ormed on the vield crown on a single scan path to examine the weld root by one half "V" path in two directions along the weld.
, 3.8.4 Record all data in accordance with the requirements of Paragraph 3.9.
3.9 Data Recordinc 3.9.1 Recording level - All indications not in.the weld or heat affected zone (HAZ) which exceed 100". DAC at the primary ref erence level shall be recorded on the ' examination data sheet. All indications in the reld and HAZ (up to 1/2 T) in excess of 50", of the primary reference level shall be re- .
corded on the examination data sheet (Figures ?A & 3B).
3.9.2 Reference Positions f or Phys' cal Measurements - u shall be '
the weld's centerline and shall be used for measuring trans-ducer movements perpendicular to the weld (See Figure 4).
3.9.2.1 Piping Within Containment - On horizontal pipe, Lo, reference shall be an axial line or point at the pipe top dead center. On vertical pipe, to ref erence shall be an axial line or point on the pipe circumference farthest from the reactor pres-sure vessel. Refer to Pipe Weld Marking Plan for guidance. ,
Page 3 of 16
QCl 6-13 Rev. A 3.9.2.2 Piping Outside Containment - On horizontal pipe,
.lo reference shall be an axial line or point at the pipe top dead center. When possible, on verti-cal pipe, the l o reference shall be selected by drawing an imaginary line down f ron the outermost radius of the next highest elevation elbow. When no elbows are in sight, the l o reference shall be an imaginary line on the pipe 3,80 degrees from the nearest wall or obstruction.
3.9.2.3 Pipe welds with indications may be stamped with a low stress V stamp. The V stamp shall be placed ca the circumferential weld centerline. The tip of the V shall be lo (for circumferential welds) and shall point in the direction from which the measurements are made. For icngitudinal piping welds, l o shall be the pipe circumferential weld centerline.
3.9.3 Methods of Recording Examination Data 3.9.3.1 The relationship between transducer movements (position's W1 , Wm W2 ), weld center (WoJ, weld reference point (Lo ), and location and length of indications (L 1 and L2 ) are shown in Figure 4.
3.9.3.2 Search unit positions W1 and U2 shall be re corded caly when the wall thickness of the pipe exceeds 1 inch.and indications are contained within the weld or lieat Af f ec ted Zone. Signals caused by geometric changes such as weld cFown, mismatch, fit-up 10 preparations, etc. , shall require recording of L1, lm, L2 Wm and the peak signal -
amplitude. The f ollowing " transducer positions" and " data to be recorded" information shall be recorded on the Examination Data Sheets for indi-cations which exceed 501 at the primary reference level (1X).
Transducer Positions Data to be Recorded
- a. W1 - Distance between Distance from refer the search unit index ence centerline (Wo ),
point and the weld to W1 )
centerline (W o) when the signal amplitude ,
increases to 50 % Indicated metal Page 4 of 16 l
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Q I 6-13 Rev. A DAC when moving to path to reflect-wards the weld. or distance,
- b. Wm - Distance between Distance from refer-the search unit index ence (Wo ), to Wm-point and the weld Indicated metal path centerline (W o) when to reflector distance, the signal amplitude is at maximum. Sign'al amplitude in %
DAC at primary refer-ence level.
- c. Wp - Distance between Distance from reft -
tiie search unit index ence centerline point and the weld (Wo ), to W2-centerline (Wo) when the signal ampli- Indicated metal tude decreases to 50% path to reflector DAC when toward ti.. distance.
weld and Wm-When indications have been identified within the weld, the transducer's positions should be recorded as f ollows:
- 1. The transducer's movement for each data point is perpend.icular to the length dimen-sion.
- 2. The data shall be obtained at 1/2 inch interval's along the length of the re-flector for indicatiens less than 2 inches in length, in addition, the maximum ampli- ,
tude points shall be che'cked at 1/4 inch intervals.
- 3. For indications greater than 2 inches in length, the data shall be taken at 1 inch intervals.
- 4. The continuity of indications between in-tervals shall be confirmed.
3.10 Review of Data The recorded data shall be reviewed by a Level 111 Examiner to determine if additional examination and/or evaluation is required.
All data shall then be processed per the applicaele QCS&I instruc-tion on the processing of data. ,
Page 5 of 16
MLA c-13 Rev. A 4.0 REFEREllCES 4.1 QCI 6-10: Requ'irements - UT Personnel, Equipment and Calibration.
5.0 ATTACH l;Ef TS 5.1 Figure 1: Pipe Calibration Block 5.2 Figure 2A: Sample Calibration Sheet 5.3 Figure 28: Sample Calibra+'an Sheet (Continued) 5.4 Figure 3A: Sample Examination Data Sheet 5.5 Figure 3B: Sample Examinatic, na ta Sheet (Continued) 5.6 Figure 4: Sample Data Recording 5.7 Figure 5: Pipe Branch Connections J
5.8 Figure 6: Pipe Branch Connections 5.9 Figure 7: Pipe Branch Connections 5.10 Figure 8: Examination Test Scans 4
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O EDC WNP-1/4 WASHCiG'NN PUBUC POWER SUPPLY SYSTEM OEoCWsP2 O EDC WNP 3/5 0 Admin rue cate: March 18, 1930 AD Edmondson TD Smith--575 KJ Hannah--575 To: ti. C. Hallas--405 DA Walker--855 From: L. W. Syverson SM fil I/4
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Subject:
UT EXAMINATI0fl 0F WNP-3 GAS STRIPPER REGEHERATIVE HEAT EXCHANGER
Reference:
An ultrasonic examination was performed on flarch 14, 1980, to detect possible longitudinal weld detects in stainless steel pipe manufactured by Youngstown Welding and Engineering Company. The affected pipe is a part of the WHP-3 Gas Stripper Regenerative Heat Exchanger shell and is identified by Heat No. 24701.
The ultrasonic examinations were performed utilizing O U and 700 angle beam transducers and a Nortec NDT-131 U1trascope. No indications were 3 observed during either examination.
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. . . . : : t This is to certify inat Larry W. Svverson is qualifisc in accordance with AS"~ Recc :erced ?ractice I:0. 5:;T-TC - 1 A ,
1975 Ecition and W??SS Procedures fcr tne U-T .iest tetr..ca . ,
_ eve.
II Certification carc f:c. 1880 Certification Date 6-21-79 r
.este:c:;cns ;o c.e rti r i ca tion t .7 :- anyj: ,
fone established .;ith examir.ation.anc is hereby authcrized to per#cen duties '.)
' hich relate to tne ebove test . method and competence levei in ccmolisace
.;ith tne AS".E Boiler and Pressure Vessei Coce.
Date[~ 2/- 77 Sicned
-..le:
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/ b[bD training Engineer Ca:e 6 2//7 7 5igned : I .'f_ _ ,p:t N!r'
/
Title:
I.DE/ISI Level ill (2)
.- , _ f,. A I
_ a te : _I. l- l'l.-
. 5ignec /f / y ,/ x / _
Title:
/ ' e p a r tr.:ea + i'.a r a ge r
.0TE (1} Add ':s n required for certifica; ion inv0lving core thar or.e test 'nethod.
(2) Foc Lecel III certifications Depar ment i'anacer appr:ca'..
.igure
'. - Certificate of 3.ami ne rs i
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, CR CE:.TIFIC;!:0 OF :OT ;E .SC . .E'_
.. T ech .i t;'. E:.2mir.iti:n Rec rd:
i cen'i's Tc. .
E 3.r-i r a .i r n Oa e 3:~c :e:13 E re D.~5 General 5-14-79 100 .3 30 Soecific 5-14-79 100 .3 30
_ Practical 5-14-79 100 .4 40 Certification l_v Ol'T1 100
- 2. Back;r:unc and E>.;er ence Record:
Babcock & Wilcox Const. Co. Inservice Inspection -
Level I Technician in UT, PT, MT 6-74 to 9-74, 3-75 to 4-75 Level I and II Technician in UT, ET, PT, MT and Vis. 6-75 to 6-78 Involved with conducting ar.d supervising ASME Section XI inspections.
Florida Power Corporation, Quality Control Inspector Level II Technician in UT, PT, MT ano Vis 8-78 to 2-79 Involved withPlanning.
Maintenance NDE and tiechanical Inspection, Procedure Writing and
- 3. Trainir; Ccurse Record:
Hutchinson Area Vo-Tech Institute Production Welding Course 11-72 to 6-73 -
Hutchinson Area Vo-Tech Institute NDE subjects.Technology Course 2000+ hours in UT, RT, ET, PT and MT and related UT-420 hours, RT-330 hours, ET-100 hours, PT-115 hours, MT-il5 hours.
Remainder in related courses Metallurgy, Welding, Acoustical Holography,
- u. Iechnical_Writino,cn
-nys.cgi - :< a r.1 r> : . Ma.nufacturing
.accrc: Processes, etc.
(See back)
Refer to this file.
E. E.: " er's ';crmer..s:
All examinations were performed in accordance with AS"E IX, Supply System Inspection Procedures, ASNT-TC-1A and the Supply System Training and Certification Procedure, 001-902.
O
. ..e CERililCAl .' Jii CT 0:A :: EPS This is to certify that Fred A. Bohnsack is cuclified in acccedance wi th AS';T P.ecommended Practice lio. ';T-TC-1A, 1975 Edition and WPPSS Procedures for the Ultrasonic Test method. L e'. e l II Certification card 110. 2566 Certi fica tio.. Ja te 2/11/30 P.es tricti.ons to Certifica tion (I f any): flone established with exar.iination and is hereby authorized to cer#orr: duties whic.h relate te the abes;e test cethod anc corpetence level in comoliance (1) with the AS 'E Boiler ana Pressure '!essel Code.
Date ll- n Signed '5b_hj,:, ~ (;' 4. f(
Title:
i;DT/ISI Training Engineer Da te._p/n/?'e Signed
Title:
I py,M1,do, ,h I;DE/ISI Level i (2)
Da te > // 15 i.' Sicred 'lf .:/r 0
Title:
x .. .
DS partment llanager
/
.0TE (1) f,dd lines as required for certification involving rcre than One test irethod.
(2) for Level Ill certifica tions Depart nent "anager acproval.
Figure 1 '- Certificate cf Examiners
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Free A. Bohnsack
,- . .. UT
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1.
Technical Exar.ina:icn T.ecccc:
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Ex2-ir.atio- Tet? ' 5 c e m. :ei :: Scare E. ace General 1-24-80 97.8 .3 29.3 Speci fic l-24-80 96 .3 28.8 Practical 1-24-80 100 .4 40 Certf. Da te 98.1
- 2. Background ar.: Ex'er.ience Rzcord:
Refer to resume in 'this certification file. -
- 3. Training Course Rccord:
Refer to resume in this certification file. .
4 Ohysical Examir.atica Re: orc:
Refer to this certification file for copy of Eye Examination .
5.
E.r.5 miner's Cerments :
The Certification Examinations were performed according to the Supply System's Certi fica tion Procedure sonics Examina tion, level II. 001-902, Table II Ultra-The Practical Examination was ccnducted OCI-6-1. according to the Supply System's Ultrasonics Procedure
.